Air supply diffusers



United States Patent AHR SUPPLY DEIFFUERS Lawrence W. Martino, 4020 New York Ave, Seaford, NY. 11783 Filed Jan. 21, 1965, Ser. No. 426,902 6 Claims. (Cl. 98-40) This invention relates generally to air supply diffusers associated with air conditioning systems. Specifically, this invention relates to an air supply diffuser which is so constructed as to minimize or entirely eliminate condensation on the surfaces thereof and thereby to protect adjacent wall, ceiling and floor structure from moisture damage.

Conventional air conditioning systems take warm moist air from an enclosed body such as a room or set of rooms, cool and dehumidify this air, and recirculate the cooled and dehumidified air to the enclosed body for the comfort and convenience of the occupants. The active components of the air conditioning system may be incorporated in the well-known roof type air conditioner which is physically located on the roof above the space or spaces served by said roof type air conditioner. When serving a set of rooms, as in a house, large apartments, hotel suites, etc., the active components of the air conditioning system may be physically located in whole or in part in a central location, as in central air conditioning systems, and communicating with each room through supply and return air ducts. Warm and humid air from a room is conducted to the central air conditioning system through a return duct or its equivalent and is cooled and dehumidified in the said central air conditioning system. This cooled and dehumidified air, which is for the purpose of this specification termed primary" air, is circulated to the room through the supply duct. Where the supply duct passes through a ceiling or wall into the room, it terminates in an air supply diffuser, by means of which primary air is introduced into the room. Conventionally, the air supply diffuser consists of a metal outer housing and a core which may have one or more fixed or adjustable vanes therein to form one air passage or a plurality of concentrically (axially) aligned air passages of various sizes, which are used to split and diffuse the entering primary air for even and controlled distribution into the room for the comfort and convenience of the occupants thereof. As the cooled primary air passes through the air supply diffuser, it cools the metallic vanes of the core and the metallic outer housing of the air sup ply diffuser. The metallic diffuser is in thermal contact with warm moist air in the room (which air is, for the purpose of this specification, termed secondary air as distinguished from the primary air passing through the air supply diffuser into the room) and, under certain circumstances, the secondary air contacting the said metallic diffuser will reach its dew point temperature causing some condensation of the water vapor carried by the secondary air. Furthermore, in the conventional air supply diffuser structure, the passage of cool and relatively dense primary air through the metallic diffuser into the room produces turbulence and eddying which, assisted by naturally occurring convective processes, causes currents of the warm and humid secondary air to be induced back into the metallic core and into thermal contact therewith and with the metallic vanes therein, which, under some circumstances, permits this secondary air which has been carried back into the core to reach its dew point temperature, causing some condensation of the water vapor carried by the said secondary air.

Reduction of the temperature of the secondary air to its dew point by the two mechanisms above described, viz., thermal contact with the metallic outer housing, and thermal contact with the interior of the metallic core including the metallic vanes or plaque therein through carryback of secondary air by turbulence, eddying and convection, causes condensed moisture to drip from the metallic diffuser to the floor below. This has in many instances caused considerable damage to ceilings, to walls, to hardwood floors and floor coverings, and even to furniture, necessitating expensive repairs and frequent redecorating.

One of the objects of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser is of improved design.

A further object of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser is thermally isolated from secondary room air in the room served by the said air supply diffuser.

Yet another object of this invention is to provide an air supply diffuser for air conditioning systems, which air supply diffuser reduces turbulence and eddying of secondary air adjacent thereto.

Still a further object of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser prevents secondary air carrying back into the diffuser to contact the core of the diffuser and the metallic vanes therein.

A further object of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser does not permit secondary air to reach its dew point temperature.

A particular object of this invention is to provide an air supply diffuser for an air conditioning system, in which the air supply diffuser connection collar is isolated thermally from the connecting ductwork supplying refrigerated air, thereby preventing the connecting ductwork from further lowering the temperature of the metallic outer housing of the air supply diffuser which is a cause of the formation of condensation.

Another particular object of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser has a peripherally thermally insulating outer rim of resilient characteristic which Will prevent air leakage between ceiling or wall and the air supply diffuser thereby preventing damage to ceilings or walls where so mounted, as well as permitting adaptation of the air supply diffuser to ceilings or walls having irregular surfaces.

Still another object of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser has a peripheral outer rim of resilient characteristic which will inhibit and/ or prevent the transmission of vibration and the resultant generation of objectionable sounds caused, for example, by a blower fan back in the connecting ductwork and provided with inadequate vibration isolators.

An object of this invention is to provide an air supply diffuser for an air conditioning system, which air supply diffuser is simple and inexpensive to manufacture, durable, and which is pleasing in appearance.

Other and further objects of this invention will become apparent during the course of the following description and by reference to the accompanying drawing and the appended claims.

Broadly, the present invention comprises a metallic air supply diffuser comprising an outer housing with a removable metallic core therein containing, in one embodiment a central air-regulating plaque and, in another embodiment a central cone, plaque or vane surrounded by one or more concentric vanes. Those metallic surfaces of the air supply diffuser which might otherwise be in contact with secondary air are isolated therefrom by means of resilient thermal insulation which encloses dead air and which acts as a very efficient heat break between the metallic surfaces of the air supply diffuser and the said secondary air, thereby preventing said secondary air from reaching its dew point temperature and condensing the moisture therein. A special shape or profile is provided for the insulation hereinbefore described when applied to the central plaque, cone or vane, so as to deflect secondary air away from the interior of the metallic core of the air supply diffuser, thereby preventing carryback of this air to the metallic surfaces of the air supply diffuser with consequent condensation of the moisture therein. The peripheral outer rim includes the hereinbefore described insulation which also acts as a gasket to prevent air leakage between the air supply diffuser and the wall or ceiling through which the same extends, as well as to act as a vibration isolator.

Referring now to the drawing, in which like numerals represent like parts in the several views:

FIGURE 1 represents a medial view in vertical section taken along the line II of FIGURE 2, showing one embodiment of the present invention.

FIGURE 2 represents a horizontal view of a circular air supply diffuser, looking upwardly at FIGURE 1.

FIGURE 3 represents a horizontal view of an air supply diffuser similar to that shown in FIGURE 2, but of rectangular or square shape.

FIGURE 4 represents a medial view in vertical section taken along the line 44- of FIGURE 5, showing another embodiment of the present invention.

FIGURE 5 represents a horizontal view of an air supply dilfuser of circular shape, looking upwardly at FIG- URE 4-.

FIGURE 6 represents a horizontal view of an air supply diffuser similar to that of FIGURE 5, but of rectangular or square shape.

In that embodiment of the invention shown in FIG- URES l and 2, a circular air supply diffuser ll extends through partition 2 (ceiling or wall) and is connected to supply duct 3 by means of connection collar 4 and screws 5, a sponge rubber gasket 6 being interposed between said supply duct 3 and connection collar 4 to thermally isolate supply duct 3 from diffuser connection collar 4 and also to act as an air seal preventing leakage through the joint between the said suply duct 3 and connection collar 4.

Air supply diffuser I comprises an outer housing 7 and a central plaque 8 which may be adjustable to vary the air flow pattern through the air supply diffuser I. As shown, threaded bolt 9 is secured to central plaque 8 and extends through threaded collar 10, the latter being secured to outer housing '7 through spider brackets II.

A thermal isolator 12, for example of molded rubber, is provided with a peripheral curved air deflector surface 13, for purposes which will hereinafter appear, and with an inner circumferential slot l4- adapted to be slipped over in engaging relationship with the lip of central plaque 8. In this manner, the thermal isolator 12 may be firmly secured to said central plaque 3. Thermal isolator 12 also comprises two separate faces or diaphragms I6 and I7, so arranged that a dead air space If; is provided between the said diaphragms l6 and 17, and another dead air space 19 is provided between diaphragm l6 and the central plaque 8. These dead air spaces 18 and 19 provide excellent thermal insulation between the said central plaque 8 and secondary air.

Thermal non-conducting rim 20, for example of molded rubber, is provided with an inner circumferential slot 21 adapted to he slipped over in engaging relationship with the lip 22 of outer housing '7. In this manner, the thermal non-conducting rim 2f! may be firmly secured to said outer housing 7. Thermal non-conducting rim includes a dead air space 23 and thus provides excellent thermal insulation between outer housing 7 and secondary air. Thermal non-conducting rim 2! is somewhat resilient, and thereby permits air supply diffuser I to be mounted without peripheral air leakage to ceilings or walls having irregular or imperfect surfaces.

In operation, cooled and dehumidified primary air, indicated by solid arrows in FIGURE 1, passes from supply duct 3 and out through air supply diffuser ll into the room or enclosed body. Warm, humid secondary air, indicated in FIGURE 1 by dashed arrows, is deflected by peripheral curved air deflector surface 13, away from the passage between thermal isolator 12 and outer housing '7, and therefore is not carried back by turbulence and eddying into air supply diffuser ll. Moreover, this warm and humid secondary air contacts only those portions of air supply diffuser I which are insulated thermally, either by thermal isolator I2 or by thermal non-conducting rim 20. In the foregoing manner, it will be seen that at no time is the warm and humid secondary air ever subjected to such temperatures as would cause the secondary air to be lowered to its dew point and, therefore, no condensation of moisture in the secondary air can occur. Also, it will be noted that any vibrations set up in supply duct 3 due for example to defective or improperly isolated blowers, etc. further back in the system, are blocked from transmission into a ceiling or wall by means of non-conducting rim 20. Moreover, it will be seen that thermal non-conducting rim 2%, by virtue of its resilience, permits the air supply diffuser l to be tightly and securely installed in ceilings (or walls) 2 having irregular or defective surfaces.

The embodiment of FIGURE 3 is essentially the same as that of FIGURES l and 2, except that the air supply diffuser la is square or rectangular in plan. It will of course be observed that the plaque to which thermal isolator 12' is mounted is not rotatably adjustable as plaque 8 in the embodiment of FIGURES l and 2.

In the embodiment of FIGURES 4 and 5, circular air supply diffuser 1b extends through ceiling or wall structure 2 and is connected to supply duct 3 by means of connecting collar 24 and screws 5, a sponge rubber gasket 7 6 being interposed between said supply duct 3 and connecting collar 24 to thermally isolate said air supply diffuser llb from the supply duct 3 and also to act as an air seal preventing leakage through the joint between the said supply duct 3 and connecting collar 24.

Air supply diffuser llb comprises an outer housing 25, a central cone or vane 26, and one or more intermediate cones or vanes 27, the said central cone or vane 26 and intermediate cones or vanes 27 being secured to outer housing in suitable fashion as by one or more spider brackets 23.

A thermal isolator 29, for example of molded rubber, is provided with inner circumferential slot 3f? adapted to be slipped over in engaging relationship with the lip of the central cone or vane 26. In this manner, the thermal isolator 29 may be firmly secured to said central cone or vane 26. Thermal isolator 29 also comprises two separate faces or diaphragms 3:1 and 32, so arranged that a dead air space 33 is provided between the said diaphragms 51 and 32, and another dead air space 34 is provided between diaphragm 32 and the central cone or vane 26. These dead air spaces 33 and 34 provide excellent thermal insulation between the said central vane or cone Z6 and secondary air. Thermal isolator 2% is further provided with a peripheral curved air deflector surface 35 for a purpose similar to that for peripheral curved air deflector surface I?) of the embodiment of FIGURES l and 2.

A thermal isolator as, for example of molded rubher, is provided with circumferential slot 37 adapted to be slipped over in engaging relationship with the lip of the intermediate vane (or vanes) 27. In this manner, the thermal isolator 36 may be firmly secured to said intermediate vane 27. Thermal isolator 36 includes a dead air space 38 and thus provides excellent thermal insulation between the intermediate vane 27 and any secondary air which may otherwise come in contact therewith.

Thermal non-conducting rim 39, for example of molded rubber, is provided with an inner circumferential slot 44) adapted to be slipped over in engaging relationship with the lip 41 of outer housing 25. In this manner, the thermal non-conducting rim 39 may 'be firmly secured to said outer housing 25. Thermal non-conducting rim 39 includes a dead air space 42 and thus pro vides excellent thermal insulation between outer housing 25 and secondary air. Thermal non-conducting rim 39 is somewhat resilient, and thereby permits air supply diffuser 1b to be tightly and securely mounted without air leakage to ceilings and walls of imperfect or irregular surface characteristics.

The operation of air supply diffuser 1b is similar to that of air supply diffuser 1 previously described.

That embodiment of air supply diffuser 1c in FIG- URE 6 is similar to air supply diffuser 1b, except that the former is square or rectangular rather than circular.

While I have shown the best embodiments of my invention now known to me, I do not wish to be limited to the exact structures herein shown and described, but may use such substitutions, modifications or equivalents as are embraced within the scope of the specification, drawing and claims.

I claim:

1. An air supply diffuser assembly adapted to pass conditioned air from a conditioned air supply duct into a room through an opening in the ceiling of said room, said air supply diffuser assembly comprising:

(a) a metallic housing adapted to be connected through the opening in the ceiling of said room to said conditioned air supply duct and mounted adjacent the underside of said ceiling, said metallic housing having a central opening therethrough communieating with an opening in said conditioned air supply duct,

(b) thermally insulating gasket means mounted to the periphery of said metallic housing and interposed between said metallic housing and the ceiling of said room,

(c) a metallic diffuser element mounted in said metallic housing along the longitudinal axis of said central opening in said metallic housing,

(d) an annular air passage between said metallic housing and said metallic diffuser element and communicating with said room,

(e) said metallic diffuser element being adapted to deflect conditioned air entering said metallic housing through the opening in said conditioned air supply duct radially of said metallic diffuser element into said annular air passage,

(f) thermal insulation means interposed between said metallic diffuser element and said room and mounted to the bottom of said metallic diffuser element and exposed to non-conditioned room air,

(g) whereby non-conditioned room air is thermally isolated from said air supply diffuser assembly to prevent condensation of moisture in said non-conditioned room air thereon.

2. An air supply diffuser assembly adapted to pass conditioned air from a conditioned air supply duct into a room through-an opening in the ceiling of said room, said air supply diffuser assembly comprising:

(a) a metallic housing adapted to be connected through the opening in the ceiling of said room to said conditioned air supply duct and-mounted adjacent the underside of said ceiling, said metallic housing having a central opening therethrough communicating with an opening in said conditioned air supply duct,

(b) thermally insulating gasket means mounted to the periphery of said metallic housing and interposed between said metallic housing and the ceiling of said room,

(c) a metallic diffuser element mounted in said metallic housing along the longitudinal axis of said central opening in said metallic housing,

(d) an annular air passage between said metallic housing and said metallic diffuser element and communicating with said room.

(e) said metallic diffuser element being adapted to deflect conditioned air entering said metallic hous ing through the opening in said conditioned air supply duct radially of said metallic diffuser element into said annular air passage,

(f) thermal insulation means interposed between said metallic diffuser element and said room and mounted to the bottom of said metallic diffuser element and exposed to non-conditioned room air, said thermal insulation means enclosing a body of dead air between said metallic diffuser element and said thermal insulation means,

(g) whereby non-conditioned room air is thermally isolated from said air supply diifiuser assembly to prevent condensation of moisture in said non-conditioned room air thereon.

3. An air supply diffuser assembly as in claim 2, said thermal insulation means comprising:

(h) first and second faces in mutual contact at their peripheries and spaced from each other inwardly of their peripheries and enclosing a second body of dead air therebetween.

4. An air supply diffuser assembly adapted to pass conditioned air from a conditioned air supply duct into a room through an opening in the ceiling of said room, said air supply diffuser assembly comprising:

(a) a metallic housing adapted to be connected through the opening in the ceiling of said room to said conditioned air supply duct and mounted ad jacent the underside of said ceiling, said metallic housing having a central opening therethrough communicating with an opening in said conditioned air supply duct,

(b) thermally insulating gasket means mounted to the periphery of said metallic housing and interposed between said metallic housing and the ceiling of said room,

(0) a metallic diffuser element mounted in said metallic housing along the longitudinal axis of said central opening in said metallic housing,

(d) an annular air passage between said metallic housing and said metallic diffuser element and communicating with said room,

(c) said metallic diff-user element being adapted to deflect conditioned air entering said metallic housing through the opening in said conditioned air supply duct radially of said metallic diffuser element into said annular air passage,

(f) a thermally insulating deflector element interposed between said metallic diffuser element and said room and mounted to the bottom of said metallic diffuser element, said thermally insulating deflector element being exposed to non-conditioned room air and having a peripheral curved surface adapted to deflect currents of non-conditioned room air away from said annular air passage,

(g) whereby non-conditioned room air is thermally isolated from said air supply diffuser assembly and currents of non-conditioned room air are diverted away from said annular air passage thereby to prevent condensation of moisture in said non-conditioned room air on said air supply diffuser assembly.

5. An air supply diffuser assembly as in claim 4, further comprising:

(h) said thermally insulating deflector element enclosing a body of dead air between said metallic diffuser element and said thermally insulating deilector element.

6. An air supply diffuser assembly as in claim 5, said thermally insulating deflector element comprising:

(i) first and second faces in mutual contact at their peripheries and spaced from each other inwardly of their peripheries and enclosing a second body of dead air therebetween.

References Cited by the Examiner UNITED STATES PATENTS Graham 984O Kisling.

Gilbert 98-40 Dauphiner 98-40 Tutt 98-40 Phillips et al. 9840 Kronrad et al. 98-40 ROBERT A. OLEARY, Primary Examiner.

W. E. WAYNER, Assistant Examiner. 

1. AN AIR SUPPLY DIFFUSER ASSEMBLY ADAPTED TO PASS CONDITIONED AIR FROM A CONDITIONED AIR SUPPLY DUCT INTO A ROOM THROUGH AN OPENING IN THE CEILING OF SAID ROOM, SAID AIR SUPPLY DIFFUSER ASSEMBLY COMPRISING: (A) A METALLIC HOUSING ADAPTED TO BE CONNECTED THROUGH THE OPENING IN THE CEILING OF SAID ROOM TO SAID CONDITIONED AIR SUPPLY DUCT AND MOUNTED ADJACENT THE UNDERSIDE OF SAID CEILING, SAID METALLIC HOUSING HAVING A CENTRAL OPENING THERETHROUGH COMMUNICATING WITH AN OPENING IN SAID CONDITIONED AIR SUPPLY DUCT, (B) THERMALLY INSULATING GASKET MEANS MOUNTED TO THE PERIPHERY OF SAID METALLIC HOUSING AND INTERPOSED BETWEEN SAID METALLIC HOUSING AND THE CEILING OF SAID ROOM, (C) A METALLIC DIFFUSER ELEMENT MOUNTED IN SAID METALLIC HOUSING ALONG THE LONGITUDINAL AXIS OF SAID CENTRAL OPENING IN SAID METALLIC HOUSING, (D) AN ANNULAR AIR PASSAGE BETWEEN SAID METALLIC HOUSING AND SAID METALLIC DIFFUSER ELEMENT AND COMMUNICATING WITH SAID ROOM, (E) SAID METALLIC DIFFUSER ELEMENT BEING ADAPTED TO DEFLECT CONDITIONED AIR ENTERING SAID METALLIC HOUSING THROUGH THE OPENING IN SAID CONDITIONED AIR SUPPLY DUCT RADIALLY OF SAID METALLIC DIFFUSER ELEMENT INTO SAID ANNULAR AIR PASSAGE, (F) THERMAL INSULATION MEANS INTERPOSED BETWEEN SAID METALLIC DIFFUSER ELEMENT AND SAID ROOM AND MOUNTED TO THE BOTTOM OF SAID METALLIC DIFFUSER ELEMENT AND EXPOSED TO NON-CONDITIONED ROOM AIR, (G) WHEREBY NON-CONDITIONED ROOM AIR IS THERMALLY ISOLATED FROM SAID AIR SUPPLY DIFFUSER ASSEMBLY TO PREVENT CONDENSATION OF MOISTURE IN SAID NON-CONDITIONED ROOM AIR THEREON. 